Self-supporting electrical fixture support

ABSTRACT

An electrical outlet box and/or assembly is attachable to the wall stud. The assembly in one embodiment includes an outlet box having a perimetrical side wall, a back wall and open front face defining a box interior. The assembly may also include a communications frame or a ceiling light box. A mounting bracket is integrally formed with the box and extends from the side wall. The mounting bracket includes, integrally formed therewith, an attachment structure for directly securing the bracket to the stud and positionally fixing the bracket without the use of additional securement hardware. The bracket may be a U-shaped member having a planar face abutting the face of the stud and a pair of spaced apart arms extending therefrom for engagement with opposite sides of the stud.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims priority to co-pending U.S. patent applicationSer. No. 60/638,224, filed Dec. 21, 2004, titled NON-METALLIC ELECTRICALBOX WITH SNAP-ON ASSEMBLY, co-pending U.S. patent application Ser. No.60/665,906, filed Mar. 28, 2005, titled SELF-SUPPORTING ELECTRICALOUTLET BOX, and co-pending U.S. patent application Ser. No. 60/670,202,filed Apr. 11, 2005, titled SELF-SUPPORTING ELECTRICAL FIXTURE SUPPORT.

FIELD OF THE INVENTION

The present invention relates generally to an electrical fixture supportsuch as an outlet box or frame. More particularly, the present inventionrelates to a non-metallic outlet box which may be secured directly tothe wall stud without use of additional installation hardware.

BACKGROUND OF THE INVENTION

Electrical outlet boxes are commonly used for terminating wires toelectrical fixtures such as switches and receptacles. Such boxes mayalso include single and multiple gang configurations and/or frames forsupporting communications fixtures. In common use, the outlet boxes areattached to a wood or metal wall stud. The outlet box must be properlypositioned on the stud so that an outer covering of wall board can beaffixed thereover.

The art has seen a wide variety of materials used to form electricaloutlet boxes. Typically, boxes are either metallic or non-metallic indesign. With respect to both types of boxes, fastening hardware isusually used to secure the box to the stud. The fastening hardware maytake the form of wood screws or nails for affixing the box to a woodstud or sheet metal screws when affixing the box to a metal stud. Ineither case, separate hardware and separate steps for securement must beemployed.

The art has also seen the use of various brackets which may be attachedto an outlet box to secure the outlet box to the stud. However, evenwhen using such brackets, the bracket itself must be fixed to the studusing securement hardware. While certain of the outlet box and bracketdesigns allow the bracket to be temporarily affixed to the stud forpositioning purposes, permanent securement of the bracket to the stud,in order to comply with applicable codes which dictate the load whichthe box must withstand, require additional securement hardware.

One such applicable code requirement is a requirement mandated byUnderwriters Laboratories (UL). UL Code 514C (29.1) requires in partthat “a bracket or other device for securing a flush device or other boxnot intended to support a fixture to a structural wall stud shallwithstand a pull of 50 pounds (222N) . . . the bracket may bend; but theresults of the test are not applicable if the bracket breaks or if thebox is pulled loose from the bracket.”

As may be appreciated, it is time consuming and costly for the installerto have to employ separate securement hardware in order to secure theoutlet box to the stud in a manner in which the box will performadequately in its intended environment and meet applicable coderequirements.

It is, therefore, desirable to provide an outlet box which may bedirectly attachable to a structural stud and which by virtue of suchattachment permanently secures the box to the stud in a manner whichmeets requisite code requirements.

SUMMARY OF THE INVENTION

The present invention provides an assembly for supporting an electricalfixture to a structural stud. The assembly includes a fixture support.The assembly further includes a mounting bracket formed integrally withthe fixture support. The mounting bracket includes integrally formedtherewith a stud attachment structure. The stud attachment structuredirectly secures the bracket to the stud without use of additionalhardware.

In preferred embodiments of the present invention, the fixture supportmay include a single or multiple gang outlet box. The fixture supportmay also include a communications fixture frame or a combination of anoutlet box and communications fixture frame.

In various embodiments, the assembly may be used with a wall or ceilingstud.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective showing of the outlet box assembly of thepresent invention.

FIG. 2 shows the outlet box assembly of FIG. 1 attached to a wall stud.

FIG. 3 is a top plan view of the outlet box assembly of FIG. 1.

FIG. 4 is front plan view of the outlet box assembly of FIG. 1.

FIG. 5 is a rear plan view of the outlet box assembly of FIG. 1.

FIG. 6 is a side plan view of the outlet box assembly of FIG. 1.

FIG. 7 shows a further embodiment of the present invention including amultiple gang outlet box.

FIG. 8 shows a still further embodiment of the present inventionincluding a single gang outlet box and a communication fixture frame.

FIG. 9 is a yet further embodiment of the present invention showing acommunication fixture frame.

FIGS. 10 and 11 show in front and back perspective views, respectively,a further embodiment of the outlet box assembly of the presentinvention.

FIGS. 12 and 13 show in front and back perspective views, respectively,a still further embodiment of the outlet box assembly of the presentinvention.

FIGS. 14 and 15 show in top and bottom perspective views, respectively,an electrical outlet box assembly of the present invention used tosupport fixtures to a ceiling stud.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS:

The present invention provides an outlet box assembly including anoutlet box and/or a communications fixture frame and an integrallyformed bracket. In a preferred embodiment, the present invention isdirected to a non-metallic outlet box formed of a suitably moldedplastic. As will be discussed in further detail hereinbelow, boxes ofthis type are typically mounted adjacent a wood stud. These wood studsare structural studs such as wall or ceiling studs. These non-metallicboxes are secured to the face of the stud by use of wood screws ornails. Such securement of the box directly to the wood stud assures thatif a load is placed on the box, it will not detach from the wood stud.For wall boxes mounted on vertical studs, such a load can be avertically directed load along the direction of the length of the studor it can be a horizontal load perpendicular thereto. In either case,the securement of the box directly to the stud by use of fasteninghardware assures that the box will not detach from its secured positionagainst the stud. The present invention provides an electrical boxassembly which secures a non-metallic electrical box to a structuralwood stud such as a wall or ceiling stud directly without need foradditional fastening hardware and which still maintains the box insecure engagement with the stud upon application of either a horizontalor vertical load.

With reference to FIGS. 1-6 of the present application, an electricaloutlet box assembly 10 is shown. Outlet box assembly 10 is preferably anon-metallic integrally formed member, typically molded of suitableplastic. The outlet box assembly 10 is designed to be self secured or“snapped” on to a wall stud 12 shown in FIG. 2. As is well known, stud12 is an elongate wooden member such as a “2×4” having a front face 12 aand opposed sides 12 b and 12 c.

Outlet box assembly 10 includes two distinct portions, an electricaloutlet box 14 and a securement bracket 16. Outlet box 14 is similar toconventional non-metallic outlet boxes well known in the art, includinga perimetrical wall 18, defined by top and bottom walls 20 and 22 andopposed lateral walls 24 and 26. Outlet box 14 has a solid back wall 28,an open front face 29, and defines a box interior 30, for accommodatingelectrical termination devices such as switches and receptacles (notshown) which terminate electrical cables (also not shown) as is wellknown in the art. While a solid box is shown in the present example, asset forth further hereinbelow, the preset invention contemplates use ofa fixture frame for supporting data/communication fixtures.

Bracket 16 is generally a U-shaped member having a planar face 32 and apair of spaced apart arms 34 and 36 extending perpendicularly therefrom.As may be appreciated from the depiction in FIG. 2, planar face 32 isdesigned for flush support against the face 12 a of stud 12, while thearms 34 and 36 are designed to extend along sides 12 b and 12 crespectively of stud 12. Also, the planar face 32 is recessed from thefront face 29 of box 14 for accommodating wall board adjacent face 32.

As more fully shown in FIGS. 3-5, the bracket 16 includes a studattachment structure 40 which extends from each of the spaced apart arms34 and 36 at opposite longitudinal ends thereof. Each stud attachmentstructure 40 includes an inwardly directed cantilevered gripping element42 surrounded by a generally rectangular frame 44 to provide structuralstability and prevent flexing of the arms thereat. The distal end ofgripping element 42 may include wood piercing teeth 42 a for engagementwith the sides 12 b and 12 c of stud 12. The gripping elements 42 arepositioned so that the bracket 16 may be attachable to the stud 12 andthereupon bite into the sides of the stud preventing removal therefrom.

Bracket 16 further includes a deflectable stiffening rib 50 at eitherdistal end thereof. Stiffening rib 50 is attached to face 32 by a livinghinge 52 (FIG. 6). This allows the stiffening rib to deflect outwardlyfrom the plane of face 32 prior to the installation of a wall covering.As will be described in further detail herein below, stiffening ribs 50help prevent the bracket from flexing upon application of a load to box14. The face 32 of bracket 16 may also include an alignment aperture 55,which is used as a viewing opening to view a scribed mark placed on theface 12 a of stud 12 by the installer for box alignment purposes.

The face 32 of bracket 16 also includes a pair of inwardly directedslots 60. Slots 60 extend from one arm 36 of assembly 10, which iscommon with lateral wall 24 of box 14. Slots 60 extend at a locationadjacent the top and bottom walls 20 and 22, partially across face 32.As will be described in further detail herein below, the slots allowdeflection of box 14 in a transverse direction indicated by arrow A inFIG. 2, without adversely affecting the grip of bracket 16 on stud 12.In addition, to also support the box on the stud during deflection,bracket 16 also includes inwardly directed fixed tooth 61 adjacent eachslot 60.

Having described the structure of the electrical outlet box assembly inthe present invention, use and operation may now be described.

Referring to FIGS. 2-4, the outlet box assembly 10 may be securelyattached to a stud 12. An installer may optionally beforehand place ascribed mark on a stud indicating the desired vertical position of thebox with respect to the stud. Thereafter, the installer snaps theassembly 10 onto the stud 12 by pushing the bracket 16 against the faceof the stud and aligning the viewing aperture 55 with the scribed mark.The bracket 16 is pushed onto the stud until the face 32 of bracket 16is supported flush against the face 12 a of stud 12. The grippingelements 42 of stud attachment structure 40 deflect allowing insertableattachment of the bracket 16 onto the stud. Thereafter, the teeth 42 adig into the wooden stud at the sides 12 b and 12 c preventingwithdrawal of the bracket from the stud. Engagement of the grippingelements 42 with the wooden stud sides prevent both horizontal andvertical movement of the outlet box assembly 10, even upon applicationof a load, either vertical as depicted by arrow B in FIG. 2, orhorizontal as depicted by arrow A.

In addition to fixedly positioning the outlet box assembly with respectto the stud, the present invention provides for the secure positioningof the outlet box with respect to the stud regardless of a load placedon the box prior to completion of the project (attachment of the wallboard). This is especially the case with respect to horizontal loadswhich may be placed on the box in a direction of arrow A such as duringwire pulling. A load placed on box 14 will not result in the bracketbecoming detached from the stud 12.

This is accomplished in one part by a provision of the stiffening ribs50. These stiffening ribs 50 extend outwardly from the plane of face 32and provide transverse stiffness to the planar face. Thus, a load placedon box 14 will not have a tendency to flex or deflect the face 32 ofbracket 16 adjacent attachment structure 40. In addition, and asimportantly, the slots 60 provide a relief area upon which a forceplaced on the box in the direction of arrow A will have a tendency topermit the box to flex forwardly. Such flexure will be absorbed by face32 of bracket 16 as the slots allow the box 14 itself be so flexed ordeflected. Moreover, upon such flexture, adjacent fixed teeth 61 willdig into the stud further gripping the bracket 16 to the stud.

The need to prevent a load placed on the box from causing detachment ofthe bracket is necessary only during the installation process. Once thewall board is attached to the stud, the ribs 50 are deflected backagainst the face 12 a of stud 12. Obviously, once the wall board isapplied, the wall board itself will restrict any excessive deflection ofbox 14.

The electrical outlet box shown in FIGS. 1-4 is a single gang electricaloutlet box. It is contemplated that the bracket of the present inventionmay be used not only with a single gang electrical outlet box, but alsowith multiple gang boxes or a communications fixture frame andcombinations thereof.

Referring to FIG. 7, a further embodiment of the present invention isshown. Outlet box assembly 110 is substantially similar to outlet boxassembly 10 shown above with respect to FIGS. 1-6. In the presentillustrative embodiment, oulet box 114 is a double gang outlet box whichaccommodates two electrical fixtures such as switches and receptacles.While a double gang box is shown, it is further contemplated that othermultiples such as a three gang box may also be employed. In all otherrespects, outlet box assembly 110 operates in a manner similar to outletbox assembly 10 of the present invention. The bracket 116 of assembly110 is identical to bracket 16 described above.

Turning now to FIG. 8, a further embodiment of the present invention isshown. Outlet box assembly 210 again is substantially similar to outletbox assembly 10 described above. In the present illustrative embodiment,box 214 includes a single gang box 214 a and a communications frame 215extending therefrom. Communications frame 215 has upper and lower arms215 a and 215 b, respectively, and a connecting side wall 215 c. Thus,the frame forms a rectangular structure with the side wall of box 214 a.As is well known in the art, frame 215 is designed to accommodate acommunications fixture which under applicable codes need not be enclosedby a box. The embodiment shown in FIG. 8 includes a single gang outletbox in combination with a communications frame. However, it iscontemplated that a multiple gang box as well as a multiple gang framemay also be employed in combination. Bracket 216 which is supported onbox 214 a is identical in structure to bracket 16 described above.

Referring now to FIG. 9, a further embodiment of the present inventionis shown. Outlet box assembly 310 includes a frame 314 attached directlyto bracket 316. The frame is a communications frame used to support acommunications fixture including upper and lower arms 314 a and 314 b,respectively, and adjoining side wall 314. Again, the frame 314 is shownfor accommodation of a single communications fixture. However, a framesupporting multiple communications fixtures may also be employed. Aswith the embodiments, bracket 316 is identical to bracket 16 describedabove and operates in identical fashion.

A further embodiment of the present invention is shown in FIGS. 10 and11. In this embodiment the outlet box assembly 150 includes anelectrical outlet box 154 and a securement bracket 156. The outlet box154 is substantially similar to outlet box 14 described above.Furthermore, securement bracket 156 is generally of a U-shaped memberhaving a planar face 160 and a pair of spaced apart arms 164 and 166extending perpendicularly therefrom. Each of the arms includes inwardlydirected cantilevered gripping element 172 which may be substantially asdescribed above with respect to gripping element 42 of FIGS. 1-9. Theplanar face 160 of bracket 156 includes a beveled peripheral edge 170.Extending therearound, the beveled edge allows for a smooth transitionwith respect to a wall board that is later positioned over the boxassembly.

A still further embodiment of the present invention is shown in FIGS. 12and 13 where an outlet box assembly 250 is shown. Outlet box assembly250 includes an outlet box 254 and a securement bracket 256. In thisembodiment, the opposite longitudinal ends of the bracket 256 includegripping elements 260. The gripping elements 260 include an angledportion 262 terminating at a point 264. The angled portion 258 anglesthe gripping elements inwardly. The gripping elements 260 allow the userto place the outlet box assembly over the structural support and holdthe assembly securely in place. Since the gripping elements 260 biasinwards toward the stud, removal of the outlet box is prevented when thepoints 264 pierce the outer surface of the stud.

While the above-referenced embodiments are all specifically directed tomounting an electrical outlet box to a wall stud, the present inventionfurther contemplates mounting an electrical outlet box to a ceilingstud.

Referring now to FIGS. 14 and 15, an electrical outlet box assembly 310is shown. Outlet box assembly 310 is preferably a non-metallic integralmember formed of suitable molded plastic. The outlet box assembly 310 isdesigned to be self-secured or snapped onto a wood ceiling stud (notshown). Outlet box assembly 310 includes an electrical outlet box 314and a securement bracket 316. The electrical outlet box 314 is somewhatof the type more fully shown and described in commonly assigned U.S.Pat. No. 6,827,229, issued Dec. 7, 2004, which is incorporated byreference herein for all purposes.

The outlet box assembly of the present embodiment may be used to securesuch devices as lighting fixtures to a ceiling stud as is known in theart. The box 314 is generally cylindrical in shape including a body 322having a planar lower surface 324. A pair of side members 326 and 328extend upwardly from either side of lower surface 324. The side members326 and 328 and the lower surface 324 define a generally U-shaped recess320 for accommodating the ceiling stud therein.

Bracket 316 is coextensive with U-shaped recess 320 of box 314. Thebracket 316 includes longitudinally spaced ends 332 and 334 extendingbeyond the box 314. Bracket 316 includes stud attachment structure 340at each of the spaced apart ends 332 and 334. Stud attachment structure340 is similar to that described with respect to the embodiments shownin FIGS. 1-9. In the present embodiment, the outlet box assembly 310 maybe secured to a ceiling stud and may be used to secure electricalfixtures therein without need for using additional securement hardwareto secure the box assembly 310 to the ceiling stud.

The present invention provides various combinations of boxes and frameswhich may be integrally supported by a bracket which allows attachmentof a box to a stud and which prevents a load placed on the box or framefor causing detachment of the bracket from the stud. Moreover, suchattachment is achieved without need for additional securement hardware.

Various changes to the foregoing described and shown structures wouldnow be evident to those skilled in the art. Accordingly, theparticularly disclosed scope of the invention is set forth in thefollowing claims.

1. An assembly for supporting an electrical fixture to a structural stud comprising: a support for terminating an electrical fixture; and a mounting bracket formed integrally with said support; said mounting bracket having formed thereon an attachment structure for directly securing and positionally fixing said bracket to the structural stud without use of additional securement hardware.
 2. An assembly of claim 1 wherein said bracket and said support are integrally molded.
 3. An assembly of claim 1 wherein said fixture support includes a single gang outlet box.
 4. An assembly of claim 1 wherein said fixture support includes a multi-gang outlet box.
 5. An assembly of claim 1 wherein said fixture support includes a communications fixture frame.
 6. An assembly of claim 1 wherein said fixture support includes an outlet box and a communications fixture frame.
 7. An outlet box assembly attachable to a structural stud comprising: an electrical outlet box having a perimetrical side wall; and a mounting bracket extending from said box; said mounting bracket having integrally formed therewith a stud attachment structure for directly securing said bracket to said stud and positionally fixing said bracket to said stud without use of additional securement hardware.
 8. An outlet box assembly of claim 7 wherein said box includes a back wall and an open front face defining a box interior for supporting an electrical fixture.
 9. An outlet box assembly of claim 8 wherein said bracket is integrally formed with said box.
 10. An outlet box assembly of claim 9 wherein said bracket extends from said side wall.
 11. An outlet box assembly of claim 7 wherein said bracket is generally a U-shaped member having a planar face positioned adjacent a face of the stud and a pair of spaced apart arms extending therefrom for engagement with opposite sides of said stud, each said arm including said stud attachment structure.
 12. An outlet box assembly of claim 11 wherein each said stud attachment structure includes an inwardly directed resilient cantilevered gripping element for engagement with said opposite sides of said stud.
 13. An outlet box assembly of claim 12 wherein said gripping elements include inwardly directed teeth for biting engagement with said stud.
 14. An outlet box assembly of claim 11 wherein said bracket includes at least one stiffening rib extending across said planar surface for preventing deflection of said bracket upon a load placed on said outlet box.
 15. An outlet box assembly of claim 14 wherein said bracket includes a pair of said stiffening ribs.
 16. An outlet box assembly of claim 14 wherein said stiffening ribs deflectably extend from said planar face.
 17. An outlet box assembly of claim 11 wherein said outlet box is deflectably supported by said bracket.
 18. An outlet box assembly of claim 17 wherein said perimetrical side wall of said outlet box includes top and bottom walls and opposed lateral walls and wherein one of said lateral walls is common to one of said arms of said bracket.
 19. An outlet box assembly of claim 18 wherein said face of said bracket includes a pair of slots extending from said common wall partially across said face and aligned with said top and bottom walls for permitting said resilient deflection of said box with respect to said bracket.
 20. An outlet box assembly of claim 7 wherein said structural stud is a wall stud.
 21. An outlet box assembly of claim 7 wherein said structural stud is a ceiling stud.
 22. A method of securing an electrical fixture to a structural stud, the electrical fixture being mounted to a support having a first side wall and a mounting bracket extending from this side wall, the mounting bracket having stud attachment structure secured thereto, the improvement comprising the step of directly mounting the bracket to the stud for securing the support to the stud and for positionally fixing the support to the stud without use of additional securement hardware.
 23. The method as set forth in claim 22 further comprising the step of integrally forming the support and the bracket.
 24. The method as set forth in claim 22 further comprising the step of forming said support and said bracket of non-metallic material.
 25. The method as set forth in claim 22 further comprising the step of forming an alignment aperture in said bracket.
 26. The method as set forth in claim 22 further comprising the step of terminating wires in said support after said support is secured and positionally fixed to the stud without the use of additional securement hardware. 